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May 22, 2023 NHTSA CAMPAIGN NUMBER: 23V361000
High-Voltage Battery May Overheat
The high-voltage battery overheating increases the risk of a fire.
NHTSA Campaign Number: 23V361
Manufacturer Polestar Automotive USA, Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 66
Summary
Polestar Automotive USA, Inc. (Polestar
) is recalling certain 2020-2021 Polestar
1 vehicles. Defective high-voltage battery
cells may cause the battery to overheat when fully charged.
Remedy
Dealers will replace the high-voltage battery pack and restore the electric driving range as necessary, free of charge. Owner notification letters are expected to be mailed July 16, 2023. Owners may contact Polestar
customer service at 1-800-806-2504. Polestar
’s number for this recall is R102316. Note: This recall supersedes Recall 22V-926 (R10216). Any vehicle that received the interim repair under Recall 22V-926 (R10202) will still need to have the remedy for 23V-361 (R10216) performed.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
RECALL R10216 DESCRIPTION
Polestar Automotive USA on behalf of Polestar
Performance AB, have decided to launch Recall R10216 on certain model year 2020 – 2021 Polestar
1 vehicles.
Polestar investigations have shown a potential issue with the high-voltage battery
in a limited number of PHEV vehicles due to a manufacturing defect, potentially leading to overheating of the battery cells when the battery is fully charged.
There is a potential risk of a fire when the battery is fully charged.
To remedy concerned vehicles, Polestar will replace all defective hardware. If a software update (R10202) to lower the battery capacity previously has been carried out, the electric driving range will be restored after the hardware replacement.
IMPORTANT NOTE: R10216 supersedes the interim solution R10202.
WHAT SHOULD YOUR CUSTOMERS DO NOW?
We have no reports of incidents related to the issue; however, we encourage customers to contact their Service Point and have this repair completed as soon as possible.
VEHICLES INVOLVED
NOTE: SERVICE POINT MUST CONFIRM VEHICLE ELIGIBILITY PRIOR TO BEGINNING THE REPAIR FOR THIS RECALL.
Vehicle eligibility must be confirmed:
- Vehicle Inquiry โ Warranty Vehicle Inquiry where the message โRecall R10216 PHEV Batteryโ will appear for eligible vehicles, F4=History from the main Inquiry menu must be selected to confirm Recall R10216 has not been completed. Eligibility can also be confirmed in VIDA.
All vehicles must be checked for any incomplete Recalls, Service Campaigns, or Service Upgrades. All open Recall, Service Campaigns or Service Action repairs must be completed.
OWNER NOTIFICATION
An owner notification will be sent out that will notify the owner of this recall instructing them to contact their Polestar Service Point and request an appointment to have this repair completed.
VEHICLES IN INVENTORY
New Vehicles in Inventory
It is a violation of federal law for a retailer to deliver any new Polestar that is eligible for a recall. Service Points are advised to check all vehicles in inventory for recall eligibility and repair immediately. Violation of this requirement by a Service Point could result in a civil penalty of up to $22,723 per vehicle.
Correct all vehicles in your new vehicle inventory before delivery.
Used Vehicles in Inventory
Polestar is ordering the stop-delivery of affected vehicles in auction and dealer inventory until the recalled item can be repaired. Stopping the delivery of affected used vehicles until the recall is complete is consistent with our commitment to safety.
What does this mean for customers?
Customers will not be able to take delivery of affected vehicles until the recall has been completed.
Chronology :
Condition considered critical by Critical Management Team 12.09.2022; Field Service Action decision confirmed by Polestar 05.17.2023; Condition detected by Internal; Number of vehicle reports with the condition reported from National Sales Company 0; Total number of cars included in vehicle reports concerning this condition 0; Implementation date of Field Service Action 05.17.2023; Extended chronology of events; Volvo
Cars inform Polestar
regarding potentially affected batteries 09.07.2022; Start technical investigation regarding potential field service action 09.21.2022; Compare PS1 cell production date with VCC population; Investigate/compare battery usage overtime; Compare hardware differences between PS1 and SPA PHEV; Considered as a critical concern by CCMT 12.09.2022; 12.14.2022 Field Service Action Part 1 (R10202 software SoC limitation) decision confirmed by CCMT; 05.17.23 Field service Action part 2 (R10216 hardware replacement) decision confirmed by CCMT.
No vehicles were repaired under R10202 (22V926) โ filed 12/15/2022.
For administration purposes the R10216 (23V361) recall will have the final remedy โ filed 5/22/23.
2 Affected Products
Vehicle
6 Associated Documents
Defect Notice 573 Report
RCLRPT-23V361-8695.PDF 215.561KB
Remedy Instructions and TSB
RCRIT-23V361-9908.pdf 459.299KB
Recall Acknowledgement
RCAK-23V361-3972.pdf 709.922KB
Recall 573 Report-Amendment 1 – 05/30/2023
RCLRPT-23V361-6921.PDF 215.656KB
Remedy Instructions and TSB
RCRIT-23V361-9404.pdf 519.352KB
Manufacturer Notices(to Dealers,etc) – May 23, 2023 Stop Sale
RCMN-23V361-8891.pdf 145.252KB
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Polestar Service and Parts Business Quality Bulletin TITLE: Recall R10216: PHEV Battery Model Year 2020-2021 Polestar
1 GROUP: 31 NO: R10216 ISSUING DEPARTMENT: Product, Safety and Compliance CAR MARKET: United States and Canada REVISIONS: ISSUE DATE: 2023-05-23 STATUS DATE: 2023-05-23 Page 1 of 3 Produced and printed in the USA and available as an electronic document. ยฉ Polestar
2023 BULLETIN REFERENCE A. RECALL R10216 DESCRIPTION B. VEHICLES INVOLVED C. PORT VEHICLES D. PARTS INFORMATION/PARTS RETURN E. OWNER NOTIFICATION F. VEHICLES IN INVENTORY G. SERVICE POINT RESPONSIBILITY H. TECHNICIAN COMPETENCY REQUIREMENT I. REIMBURSEMENT PROCEDURES & ALLOWANCE A. RECALL R10216 DESCRIPTION Polestar
Automotive USA on behalf of Polestar
Performance AB, have decided to launch Recall R10216 on certain model year 2020 – 2021 Polestar
1 vehicles. Polestar
investigations have shown a potential issue with the high-voltage battery
in a limited number of PHEV vehicles due to a manufacturing defect, potentially leading to overheating of the battery cells when the battery is fully charged. There is a potential risk of a fire when the battery is fully charged. To remedy concerned vehicles, Polestar
will replace all defective hardware. If a software update (R10202) to lower the battery capacity previously has been carried out, the electric driving range will be restored after the hardware replacement. IMPORTANT NOTE: R10216 supersedes the interim solution R10202. Page 2 of 3 2023-05-23 Quality Bulletin R10216 WHAT SHOULD YOUR CUSTOMERS DO NOW? We have no reports of incidents related to the issue; however, we encourage customers to contact their Service Point and have this repair completed as soon as possible. B. VEHICLES INVOLVED NOTE: SERVICE POINT MUST CONFIRM VEHICLE ELIGIBILITY PRIOR TO BEGINNING THE REPAIR FOR THIS RECALL. Vehicle eligibility must be confirmed: โข Vehicle Inquiry โ Warranty Vehicle Inquiry where the message โRecall R10216 PHEV Batteryโ will appear for eligible vehicles, F4=History from the main Inquiry menu must be selected to confirm Recall R10216 has not been completed. Eligibility can also be confirmed in VIDA. All vehicles must be checked for any incomplete Recalls, Service Campaigns, or Service Upgrades. All open Recall, Service Campaigns or Service Action repairs must be completed. C. PORT VEHICLES NOT all eligible vehicles arriving from the ports will have this recall completed. Vehicle eligibility must be confirmed as outlined in Step B. above. D. PARTS / PARTS RETURN Please refer to Parts Bulletin R10216. E. OWNER NOTIFICATION An owner notification will be sent out that will notify the owner of this recall instructing them to contact their Polestar
Service Point and request an appointment to have this repair completed. F. VEHICLES IN INVENTORY New Vehicles in Inventory It is a violation of federal law for a retailer to deliver any new Polestar
that is eligible for a recall. Service Points are advised to check all vehicles in inventory for recall eligibility and repair immediately. Violation of this requirement by a Service Point could result in a civil penalty of up to $22,723 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. Used Vehicles in Inventory Polestar
is ordering the stop-delivery of affected vehicles in auction and dealer inventory until the recalled item can be repaired. Stopping the delivery of affected used vehicles until the recall is complete is consistent with our commitment to safety. What does this mean for customers? Customers will not be able to take delivery of affected vehicles until the recall has been completed. 2023-05-23 Page 3 of 3 Quality Bulletin R10216 G. SERVICE POINT RESPONSIBILITY All vehicles qualifying for this recall must be repaired prior to a customer taking possession of the vehicle. H. TECHNICIAN COMPETENCY REQUIREMENT The technician competency requirement for this campaign repair is 3EB. I. REIMBURSEMENT PROCEDURES & ALLOWANCE Recall R10216 claims should be submitted using the LONG FORM application only. Claim Type: R10216 Cause Code: 02 CSC Code: XW Main OP: 97916-2 Failed Part No: 36003341 (Cell Module, Exchange) Operation Number Repair Description Qty Models Labor Time 97916-2 Cell Modules replace acc. TO QB 1 Polestar
1 19.9 IMPORTANT NOTE: Software should be downloaded in this order: 1. Software Product for returning SoC level to 100%. 2. Reset HV Battery
cell Capacity by VIDA using: VIDA path: Diagnostics/Components/Control modules/Battery Energy Control Module/ (BECM)/ Diagnostic sequences/Resetting the state of health 3. Total Upgrade No balancing is needed when replacing all modules as in the QB. Coolant is to be re-used according to VIDA instruction, eventual top up is considered a consumable. *Labor times provided are current at the time of release and are subject to change: Claims will be paid at the time in effect on the repair date.
**************************************************************************************************************
Produced and printed in the USA and available as an electronic document. ยฉ Polestar 2023 Polestar
Service and Parts Business Parts Bulletin TITLE: Recall R10216: PHEV Battery Model Year: 2020-2021 Polestar
1 GROUP: 31 NO: R10216 CAR MARKET: United States and Canada REVISIONS: ISSUE DATE: 2023-05-23 STATUS DATE: 2023-05-23 Page 1 of 2 Reference Bulletins: QB R10216 Polestar
Automotive USA on behalf of Polestar
Performance AB, have decided to launch Recall R10216 on certain model year 2020 – 2021 Polestar
1 vehicles. Polestar
investigations have shown a potential issue with the high-voltage battery
in a limited number of PHEV vehicles due to a manufacturing defect, potentially leading to overheating of the battery cells when the battery is fully charged. There is a potential risk of a fire when the battery is fully charged. To remedy concerned vehicles, Polestar
will replace all defective hardware. If a software update (R10202) to lower the battery capacity previously has been carried out, the electric driving range will be restored after the hardware replacement. The following part numbers apply: Part Number Description Qty 36003341 Cell Module Exchange 18 8672278 Gasket 1 985868 Flange Lock Nut 2 30670577 Sems Screw 2 998157 Cable Tie 1 32202623 Gasket 1 Page 2 of 2 2023-05-23 Parts Bulletin 31-R10216 Part Number Description Qty 32202628 Gasket 1 32202627 Gasket 1 31673969 Gasket 1 985899 Flange Lock Nut 8 985865 Flange Lock Nut 5 985866 Flange Lock Nut 12 31407048 Plug 2 999354 Flange Lock Nut 93 31308539 Sealing 6 32137209 Total Upgrade PS1 1 32397661 SoC 80% to SoC 100% 1
**************************************************************************************************************
STEVE DEGRAZIO โ HEAD OF QUALITY, CAR SERVICE & REPAIR EXPERIENCE, NORTH AMERICA May 23, 2023 Subject: Recall R10216 TO: All U.S and Canadian Sales and Service Points NEW VEHICLES IN RETAILER INVENTORY It is a violation of federal law for a retailer to deliver any new Polestar that is eligible for a recall. Service Points are advised to check all vehicles in inventory for recall eligibility and repair immediately. Violation of this requirement by a Service Point could result in a civil penalty of up to $22,723 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. USED VEHICLES IN INVENTORY Polestar
is ordering the stop-delivery of affected vehicles in auction and inventory until the recalled item can be repaired. Stopping the delivery of affected used vehicles until the recall is complete is consistent with Polestar
โs commitment to safety. Additionally, while Federal law does not prohibit the sale of used vehicles with open recalls, the sale of such cars could violate certain state laws and create liability on behalf of the service point. What does this mean for customers? Customers will not be able to take delivery of affected vehicles until the recall has been completed. When will this be resolved? Polestar
Automotive USA on behalf of Polestar
Performance AB, have decided to launch Recall R10216 on certain model year 2020 – 2021 Polestar
1 vehicles. Polestar
investigations have shown a potential issue with the high-voltage battery
in a limited number of PHEV vehicles due to a manufacturing defect, potentially leading to overheating of the battery cells when the battery is fully charged. There is a potential risk of a fire when the battery is fully charged. To remedy concerned vehicles, Polestar
will replace all defective hardware. If a software update (R10202) to lower the battery capacity previously has been carried out, the electric driving range will be restored after the hardware replacement. IMPORTANT NOTE: R10216 supersedes the interim solution R10202. Polestar
Automotive USA Inc. 777 MacArthur Blvd Page 1 of 2 Mahwah, NJ 07430 Telephone +1-201-981-7066 Vehicle eligibility must be confirmed: โข Vehicle Inquiry โ Warranty Vehicle Inquiry where the message “Recall R10216 PHEV Batteryโ will appear for eligible vehicles, F4+History from the main Inquiry menu must be selected to confirm Recall R10216 has not been completed. Eligibility can also be confirmed in VIDA. โข Recall R10216 eligible vehicles not yet delivered to end customers must be corrected prior to delivery. All vehicles must be checked for any incomplete Recalls, Service Campaigns, or Service Upgrades. All open Recall, Service Campaigns or Service Action repairs must be completed. OWNER NOTIFICATION An owner notification will be sent out that will notify the owner of this recall instructing them to contact their Polestar
Service Point and request an appointment to have this repair completed. PORT VEHICLES NOT all eligible vehicles arriving from the ports will have this recall completed. Vehicle eligibility must be confirmed. PARTS / PARTS RETURN Please refer to Parts Bulletin R10216 which will be released shortly. CLAIM SUBMISSION A Quality Bulletin will be released shortly. Please refer to the claim submission information in the Quality Bulletin. SERVICE POINT RESPONSIBILITIES Service Point must perform this recall campaign on eligible vehicles regardless of miles/kilometers or vehicle age. All work performed under this recall is free of charge to the owner. As the safety of our customers is our utmost priority, we are taking full responsibility to ensure the highest quality and safety standards for our cars. If you have questions about this recall or any other field service action, please contact me or any member of our Customer Experience Center. Your cooperation in completing this important recall is greatly appreciated. Best regards, Steve DeGrazio Head of Quality, Car Service & Repair Experience, North America 201-981-7066 Steve.degrazio@polestar
.com Page 2 of 2
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-361 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Polestar Automotive USA, Inc. Submission Date : MAY 22, 2023 NHTSA Recall No. : 23V-361 Manufacturer Recall No. : R10216 Manufacturer Information : Manufacturer Name : Polestar
Automotive USA, Inc. Address : 1 Volvo
Drive ROCKLEIGH NJ 07647 Company phone : 999 Population : Number of potentially involved : 66 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2020-2021 Polestar
1 Vehicle Type : LIGHT VEHICLES Body Style : 2-DOOR Power Train : HYBRID ELECTRIC Descriptive Information : Concerned vehicles are certain 2020-2021 Polestar
1 vehicles from start of production for PHEV vehicles with Forever Energy batteries produced in China. The end breakpoint is based on Computed Tomography scans, battery tear down and physical testing. A fault in the battery cells may cause a thermal event or fire when the high-voltage battery
is fully charged. This is a suppliersโ responsibility due to a manufacturing defect which occurred during a specific production period at the battery supplierโs production line for battery cells. 66 Vehicles in the U.S. are affected. Production Dates : SEP 11, 2019 – MAY 12, 2021 VIN Range 1 : Begin : LYVPKBDTDLB000109 End : LPSBE0YL8MB001019 โ Not sequential Description of Defect : Description of the Defect : Polestar
investigations has shown a potential issue with the high-voltage battery
in a limited number of PHEV vehicles due to a manufacturing defect, potentially leading to overheating of the battery cells when the battery is fully charged. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : There is a risk of a potential fire when the high-voltage battery
is fully charged. Description of the Cause : The root cause is a manufacturing defect which occurred during a specific production period at the battery supplierโs production line for battery cells. Identification of Any Warning that can Occur : The customer will receive no warnings prior to overheating of battery cells. Part 573 Safety Recall Report 23V-361 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 Involved Components : Component Name 1 : Forever Energy High-voltage battery
cells. Component Description : High-Voltage Battery
Component Part Number : NR Supplier Identification : Component Manufacturer Name : Zhejiang Forever New Energy Technology C Address : No 589 Longtan Rd. HIGH-TECH INDUSTRY PA Jinhua Foreign States 321000 Country : China Chronology : Condition considered critical by Critical Management Team 12.09.2022; Field Service Action decision confirmed by Polestar
05.17.2023; Condition detected by Internal; Number of vehicle reports with the condition reported from National Sales Company 0; Total number of cars included in vehicle reports concerning this condition 0; Implementation date of Field Service Action 05.17.2023; Extended chronology of events; Volvo
Cars inform Polestar
regarding potentially affected batteries 09.07.2022; Start technical investigation regarding potential field service action 09.21.2022; Compare PS1 cell production date with VCC population; Investigate/compare battery usage overtime; Compare hardware differences between PS1 and SPA PHEV; Considered as a critical concern by CCMT 12.09.2022; 12.14.2022 Field Service Action Part 1 (R10202 software SoC limitation) decision confirmed by CCMT; 05.17.23 Field service Action part 2 (R10216 hardware replacement) decision confirmed by CCMT. Description of Remedy : Description of Remedy Program : To remedy concerned vehicles, Polestar will replace all defective hardware. If a software update (R10202) to lower the battery capacity previously has been carried out, the electric driving range will be restored after hardware replacement. R10216 supersedes the interim solution R10202 (NHTSA ID 22V926) & (TC 2022-716). How Remedy Component Differs from Recalled Component : Concerned vehicles were certain 2020-2021 Polestar 1 vehicles which will receive new hardware. Part 573 Safety Recall Report 23V-361 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 Identify How/When Recall Condition was Corrected in Production : Production of the Polestar 1 has ended, and the hardware replacement is the final service solution. Recall Schedule : Description of Recall Schedule : Remedy Notices Planned Dealer Notification Date : MAY 22, 2023 – MAY 22, 2023 Planned Owner Notification Date : JUL 16, 2023 – JUL 16, 2023 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-361 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Polestar Automotive USA, Inc. Submission Date : MAY 30, 2023 NHTSA Recall No. : 23V-361 Manufacturer Recall No. : R10216 Manufacturer Information : Manufacturer Name : Polestar Automotive USA, Inc. Address : 1 Volvo Drive ROCKLEIGH NJ 07647 Company phone : 999 Population : Number of potentially involved : 66 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2020-2021 Polestar 1 Vehicle Type : LIGHT VEHICLES Body Style : 2-DOOR Power Train : HYBRID ELECTRIC Descriptive Information : Concerned vehicles are certain 2020-2021 Polestar 1 vehicles from start of production for PHEV vehicles with Forever Energy batteries produced in China. The end breakpoint is based on Computed Tomography scans, battery tear down and physical testing. A fault in the battery cells may cause a thermal event or fire when the high-voltage battery
is fully charged. This is a suppliersโ responsibility due to a manufacturing defect which occurred during a specific production period at the battery supplierโs production line for battery cells. 66 Vehicles in the U.S. are affected. Production Dates : SEP 11, 2019 – MAY 12, 2021 VIN Range 1 : Begin : LYVPKBDTDLB000109 End : LPSBE0YL8MB001019 โ Not sequential Description of Defect : Description of the Defect : Polestar investigations has shown a potential issue with the high-voltage battery
in a limited number of PHEV vehicles due to a manufacturing defect, potentially leading to overheating of the battery cells when the battery is fully charged. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : There is a risk of a potential fire when the high-voltage battery
is fully charged. Description of the Cause : The root cause is a manufacturing defect which occurred during a specific production period at the battery supplierโs production line for battery cells. Identification of Any Warning that can Occur : The customer will receive no warnings prior to overheating of battery cells. Part 573 Safety Recall Report 23V-361 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 Involved Components : Component Name 1 : Forever Energy High-voltage battery
cells. Component Description : High-Voltage Battery
Component Part Number : NR Supplier Identification : Component Manufacturer Name : Zhejiang Forever New Energy Technology C Address : No 589 Longtan Rd. HIGH-TECH INDUSTRY PA Jinhua Foreign States 321000 Country : China Chronology : Condition considered critical by Critical Management Team 12.09.2022; Field Service Action decision confirmed by Polestar 05.17.2023; Condition detected by Internal; Number of vehicle reports with the condition reported from National Sales Company 0; Total number of cars included in vehicle reports concerning this condition 0; Implementation date of Field Service Action 05.17.2023; Extended chronology of events; Volvo
Cars inform Polestar regarding potentially affected batteries 09.07.2022; Start technical investigation regarding potential field service action 09.21.2022; Compare PS1 cell production date with VCC population; Investigate/compare battery usage overtime; Compare hardware differences between PS1 and SPA PHEV; Considered as a critical concern by CCMT 12.09.2022; 12.14.2022 Field Service Action Part 1 (R10202 software SoC limitation) decision confirmed by CCMT; 05.17.23 Field service Action part 2 (R10216 hardware replacement) decision confirmed by CCMT. No vehicles were repaired under R10202 (22V926) โ filed 12/15/2022. For administration purposes the R10216 (23V361) recall will have the final remedy โ filed 5/22/23. Part 573 Safety Recall Report 23V-361 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 Description of Remedy : Description of Remedy Program : To remedy concerned vehicles, Polestar will replace all defective hardware. If a software update (R10202) to lower the battery capacity previously has been carried out, the electric driving range will be restored after hardware replacement. R10216 supersedes the interim solution R10202 (NHTSA ID 22V926) & (TC 2022-716). How Remedy Component Differs from Recalled Component : Concerned vehicles were certain 2020-2021 Polestar 1 vehicles which will receive new hardware. Identify How/When Recall Condition was Corrected in Production : Production of the Polestar 1 has ended, and the hardware replacement is the final service solution. Recall Schedule : Description of Recall Schedule : Remedy Notices Planned Dealer Notification Date : MAY 22, 2023 – MAY 22, 2023 Planned Owner Notification Date : JUL 16, 2023 – JUL 16, 2023 * NR – Not Reported
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